War Stories

InterCoat® ChemGuard in Action
We are adding customer successes every day.  Users of carbon steel for over 80 years have tried to resist the effects of corrosion using zinc in increasingly heavier coatings, and then adding chemical treatments such as dangerous hexavalent chrome, oil and other compounds to further hold off the rust, even if only for transportation and storage before manufacture.

Our customers fight the war, battling corrosion and zinc failure with InterCoat® ChemGuard.

Some examples:

Non-Structural Studs

With zinc premiums higher every year, the use of automotive galvanneal provides some savings. The real boost comes from reduced zinc weights, better protection, and the amazing ability to cold reduce the material without losing the InterCoat®ChemGuard layer.  It is this material in the astonishing photos on our TRUE STORY section where the studs were left outdoors in Gary, Indiana for a year and still look brand new.

Defense Barriers

A contractor for military installations overseas used large, 6-8 foot defensive infrastructure barriers bolted together and buried at an angle. These barriers provide additional defense against vehicular attack. Initially using HDG G235, they discovered better corrosion protection and reducible cost using G90 with InterCoat®ChemGuard.

School Bus Floors

It’s hard not to track in the outdoor elements onto a school bus in winter. The mixture of snow, slush, and salt with cleaning compounds accelerates the corrosion of school bus stairs and driver floors. With InterCoat®ChemGuard our client is now offering an “extreme weather” package for northern and coastal state customers and those forward-thinking customers looking to improve protection. This change gives their customers a unique technological advantage over competitors and provides a higher quality, longer lasting product. Read the Modern Metals article here!

Something Is Coming That Will Change Galvanize Forever

Fiber Drum Rings

Our client found that a lighter zinc coating weight with InterCoat®Chemguard  provided superior protection and formability.

Solar Racking

A client manufacturing structural supports for solar panels outdoors and exposed to elements was using G235 with hexavalent chrome. When not compelled by government constraints, they found that using G40 with InterCoat®Chemguard to be superior in corrosion performance and far more cost effective. The client is now providing it to their customers.

Automotive Brake System

In 2016, a customer was stamping parts for an antilock brake system (ABS) that after two passes in cleaning stages, had to pass a particulate count in order to be used in this application. After a parts cleaner and an ultrasonic cleaner, they had challenges consistently reaching the standard. Testing a new material coated with InterCoat®ChemGuard surpassed not only the 2016 standards but the newer, stricter standards possible in future years. InterCoat®ChemGuard cannot be removed from the zinc, after a parts cleaner and an ultrasonic cleaner – it provided the customer with a cleaner, more protective surface. The covalent bond wins again!

Automotive Manufacturer #1

Situation: One US auto maker had an under the hood electro-galvanized part that was being processed with oil. The part had to be sent out to another company to be washed, dried, packed in plastic, and shipped to Mexico for installation into the car.

Problem: No matter how dry they got the part, it had pin dots of white rust by the time it was received in Mexico.

Solution: Coat the EG part with InterCoat® ChemGuard. With the coating acting as a dry film lubricant, they processed the part dry. No need to send it out to be washed. They could immediately pack the part and ship it out. The parts arrived in Mexico in pristine condition.

Automotive Manufacturer #2

Situation: One US automaker had an electro-galvanized engine part that was being processed with oil. It needed to have a gasket adhered to the perimeter of the part.

Problem: Regardless of how dry they got the surface of the part, they could not get complete adhesion of the gasket because of oil residue.

Solution: By coating the metal with InterCoat® ChemGuard, they could process the part dry. This insured that they could get complete adhesion of the gasket.

Fiber Drum Export

A customer shipping fiber drums overseas was having tremendous corrosion issues on the top and bottom trim rings. They were using electro-galvanized but it simply wasn’t enough protection for the journey. One option was hot dip galvanized but there was too much flaking while the ring was being processed. Another option would be stainless steel but as you can imagine, the cost made this prohibitive. In the end, they found that taking the original electro-galvanized, coated with InterCoat® ChemGuard, gave them the protection that they needed on a cost-effective product that could withstand the manufacturing process.